Electromagnetic relay having parts retained by a one-piece spring clip which also provides armature bias



Oct. 15, 1968 P. J. LE MAUVIEL ELECTROMAGNETIC RELAY HAVING PARTS RETAINED BY A ONE-PIECE SPRING CLIP WHICH ALSO PROVIDES ARMATURE BIAS 2 Sheets-Sheet 1 Filed May 11, 1966 M/l EA/TOR PAUL J LE MAUV/EL o/9ao 21 026 L I. iiEli l'iiia 1963 P. J. LE MAUVIEL 3,

ELECTROMAGNETIC RELAY HAVING PARTS RETAINED BY A ONE-PIECE SPRING CLIP WHICH ALSO PROVIDES ARMATURE BIAS Filed May 11, 1966 2 Sheets-Sheet 2 INVENTOR. PAUL J. LE MAUV/EL United States Patent 3,406,361 ELECTROMAGNETIC RELAY HAVING PARTS RE TAINED BY A ONE-PIECE SPRING CLIP WHICH ALSO PROVIDES ARMATURE BIAS Paul J. Le Mauviel, Asheville, N.C., assignor to Square D Company, Park Ridge, 111., a corporation of Michigan 7 Filed May 11, 1966, Ser. No. 549,257

13 Claims. (C1. 335--178) ABSTRACT OF THE DISCLOSURE The armature of a miniature clapper-type relay is retained in pivotal engagement with the frame of the relay by a one-piece generally U-shaped spring clip which also secures the frame to the relay base without the need for additional fastening means. The spring clip includes a portion having a tab member which biases the armature toward its normal position away from the relay core and which holds the armature'in that position when the relay is unenergized. 1

This invention relates to electromagnetically operated switches, and more particularly to a miniature electromagnetic relay. i

' The principal object of this invention is to provide an improved miniature electromagnetic relay in which a magnet and coil sub-assembly, an armature and contact actuator sub-assembly, and a contact and base unit are secured together in operative realtionship solely by a spring clip which also serves as a biasing means for the armature.

A further object of this invention is to provide an electromagnetic relay comprising a magnet frame, a magnet core secured to the frame, a coil surrounding the core,

an armature pivotally engaging the frame for movement toward and away from the core, a supporting base, contact means supported by the base, a contact actuator carrie'd-by the armature and movable therewith, and a unitary spring clip securing the frame to the base and retaining' the armature in pivotal engagement with the frame, the spring clip including biasing means urging the armature away from the core and urging the contact actuator to a position in engagement with the contact means.

' Other objects and advantages will become apparent from the following specification wherein reference is made to the drawings, in which:

FIG. 1 is a side elevation of a relay in accordance with this invention showing the relaymounted on a pin-type plug-in connector and enclosed in a protective cover, portions of the relay and cover being shown in section for clarity, the sectionalized portion of the relay being taken as indicated at 11 in FIG. 2;

FIG. 2 is a front elevation of the relay of FIG. 1, the plug-in connector and protective cover being removed and a portion of the relay being shown in section for clarity;

FIG. 3 is a sectional view taken generally as indicated at 3-3 in FIG. 2 and'showing the contact and base subassembly unit separated from the remainderof the relay of FIG. 1;

FIG. 4 is a side elevation of the magnet and coil subassembly of the relay;

FIG. 5 is an exploded perspective view of the relay of FIG. 1;

FIG. 6 is an exploded perspective view of the magnet frame and core of the relay of FIG. 1; and

FIG. 7 is a perspective view of an alternative form of the relay arranged for manual operation, a portion of the protective cover being removed and parts of the relay being omitted for clarity of illustration.

Referring to the drawings, a miniature relay in accordance with this invention comprises a contact and base unit 10 (shown separately in FIG. 3), an armature and actuator'sub-assembly 11, and a magnet and coil sub-assembly 12 (shown separately in FIG. 4) secured together by a spring clip or frame clip 14, preferably formed of stainless steel. The contact and base unit 10, shown best in FIGS. 3 and 5, includes contact means comprising, for the three pole relay shown, three electrically conductive contact assemblies 15. Each contact assembly 15 comprises a double-faced movable contact 16 carried at the free end of one arm of a refiexed contact spring 17 having its other arm secured to an elongated movable contact bracket 19 as by spot welding or the like. Each contact bracket 19 is provided with a pair of longitudinally spaced projections 20which are received respectively in complementary openings in its associated contact spring 17 thereby positioning the spring 17 in proper alignment with respect to its bracket 19.

The movable contact 16 for each pole is double-faced, as previously mentioned, and has a contact surface disposed on each side of its associated spring 17 for selective engagement with an associated pair of opposed stationary contacts 21 and 22 between which each movable contact 16 is positioned for operation. The contacts 21 and 22 of each pole are carried by a pair of stationary contact brackets 24 and 25, respectively, and the brackets 24 and 25 together with the contact brackets 19 extend through, and are retained by epoxy or other suitable means in, respective openings 27 formed in an insulating base member 26 preferably molded of a phenolic compound.

Although the miniature relay described herein has three poles as is apparent from FIGS. 2 and 5, it could, if desired, be constructed as a two-pole device by omitting the components comprising the center pole, each pole being identically constructed.

The contact brackets 19, 24 and 25 for each pole have terminal portions 19a, 24a, and 25a, respectively, which project downwardly beyond a lower face of the base member 26. Because each pole of the relay has three terminal portions, the three-pole relay shown has, for its switching circuits, a total of nine terminal portions spaced in three rows of three each. Electrical connections may be made to the terminal portions 19a, 24a, and 25a by plugging the base member 26 and its associated terminal portions into a conventional pre-wired socket receptacle (not shown) which receives the terminal portions 19a, 24a, and 25a in respective complementary receptacles. Alternatively, the relay may be mounted on a panel or other structure with electrical connections made by soldering wires directly to the terminal portions of the relay. A third manner of connecting the relay for use in an external circuit is indicated in FIG. 1 wherein the relay is shown with its terminal portions 19a, 24a, and 25a electrically connected to an eleven pin radio-type plug-in connector 29 provided with pins 30, nine of the pins 30 being electrically connected by wires 31 to the respective terminal portions of the relay, the remaining two pins 30 being electrically connected to the magnet and coil subassembly as will be described.

The magnet and coil sub-assembly 12, the armature and actuator sub-assembly 11, and the contact and base unit 10 are preferably made as separate assemblies which are firmly secured together in operative relationship by the frame clip 14. This arrangement of separate assemblies simplifies and expedites manufacture and facilitates ready separation of the components for adjustment or repair. Of particular advantage is that the movable and'stationary contacts are exposed so as to permit convenient adjustment thereof prior to final assembly.

Referring now principally to FIGS. 4 and 5, the magnet and coil sub-assembly 12 comprises a magnet frame 32 having a substantially flat rear portion 34 with bent over top and bottom portions 35 and 36, respectively. The top frame portion 35 is provided with a pair of forwardly directed flank portions 37 which, together with an intermediate forward edge face 35a (FIGS. and 6) of the top frame portion 35, define a shallow recess for receiving the armature and actuator sub-assembly 11 in juxtaposition with the frame 32. The top frame portion 35 also has a pair of upwardly directed projections 38'and the bottom frame portion 36 has a downwardly directed projection 39, the purpose of the projections being later explained.

A laminated core 40 comprising a plurality of ferrous magnetizable laminations 41 is secured in an opening 42 (FIG. 6) in the rear frame portion 34 by staking or otherwise deforming the laminations after they have been positioned with respect to the frame portion 34. As best illustrated in FIGS. 4 and 5, an operating winding or coil 43 having a plurality of turns of insulated electrically conductive wire wound on an insulating bobbin 44 and provided with a pair of terminals 45, only one of which is shown, is received coaxially on the core 40. The coil 43 is fixedly retained in the sub-assembly 12 by a highly conductive shading coil 46, a portion of which is received in a notch 47 in the forward face of the core 40 and thereafter staked or otherwise deformed as indicated at the numeral 48 in FIG. 4 to securely wedge the shading coil 46 in place. The purpose of the shading coil 46 is well known to those skilled in the art and need not be further explained. The rear frame portion 34 also has a pair of downwardly directed leg members 34a and 34b (FIG. 6) integral with the frame 32 and disposed one on each side of the bent over bottom 'frame portion 36. An upwardly directed car 49 also extends contiguously from the rear frame portion 34 as an integral section thereof. As is apparent from an examination of FIG. 6, the frame 32 can preferably be blanked from a single flat piece of metal stock and thereafter be formed by bending the top and bottom frame portions 35 and 36 without the necessity of further fabrication.

Referring now to FIGS. 1, 2, and 5, the armature and actuator sub-assembly 11 comprises an insulating non-conductive contact actuator 50, preferably molded of a phenolic compound, fixedly secured to a generally rectangular shaped essentially flat armature 51 by a suitable adhesive or, alternatively, by a pair of rivets '52 received through aligned complementary openings in the actuator and armature. A narrowed upper portion 54 of the armature 51 defining, and disposed intermediate of, a pair of shoulders 55 has a pair of transversely aligned slots 56 spaced upwardly from the shoulders 55 a distance substantially equal to the thickness of the top frame portion 35 and opening into the marginal edges of the portion 54. The actuator 50, when the armature and actuator sub-assembly 11 is installed in operative relation with the magnet and coil sub-assembly 12 and with the contact and base unit as illustrated in FIGS. 1 and 2, is positioned for operative engagement with the contact springs 17 so as to move the contacts 16 between their associated stationary contacts 21 and 22. A pair of spaced barriers 50a molded integrally with, and extending forwardly of, the actuator 50 provides increased electrical clearance intermediate the areas of contact between the actuator 50 and the springs 17 where dust accumulation may occur.

As previously mentioned, the spring steel frame clip 14 holds the sub-assemblies of the relay securely in operative engagement. 'In addition, the frame clip 14 serves to bias the armature and actuator sub-assembly 11 forwardly away from the core 40. As is best illustrated in FIG. 5, the frame clip 14 comprises two bent over leg portions 60 disposed generally parallel to each other and formed integrally with, and joined by, a bowed central portion or yoke 61 having a pair of holes or apertures '62 therein which are shaped to receive the projections 38 of the top frame portion 35. The apertures 62 and the projections 38 thus comprise mutually interengaging means for constraining the clip 14 in alignment with the frame 32.

Each of the leg portions 60 has a rectangular shaped portion removed therefrom so that each leg portion comprises a pair of elongated members 60a joined at their ends remote from the yoke 61 by a connecting or bight portion 6%. A forward overhanging portion 64 of the clip 14 has an upwardly directed'armature biasing tab member 65 and includes a pair of bent-over knee portions 66 joining the overhanging portion 64 to the forward marginal area of the yoke 61. The portion 64, including the tab member 65 and the knee portions 66, comprises biasing means for urging the armature and actuator sub-assembly 11 forwardly away from the core 40.

As in the case of the frame 32, the entire frame clip 14 is blanked from a single flat sheet of steel, the leg portions 60 and the overhanging portion 64 being thereafter formed by one or more bending operations.

The bending into position of the overhanging portion 64 after appropriate blanking defines an opening 67 between a forward edge face 61a of the yoke 61 and the tab member '65, the opening 67 being bounded adjacent the knee portions '66 by respective transversely aligned recesses 69 which have a width slightly greater than the thickness of the armature 51. I

To assemble the relay, the upper portion 54 of the armature 51 is positioned in the opening 67 of the frame clip 14 so that the slots 56 in the upper portion of the armature are disposed adjacent the knee portions 66 at the recesses 69. Thus positioned, the armature and actuator sub-assembly 11 and the frame clip 14 can be fitted into assembled relationship with the magnet and coil sub-assembly 12, the frame clip 14 being received over the sub-assembly '12 with the leg portions 60 of the clip 14 straddling the coil 43 and with the projections 38 of the top frame portion 35 received in the apertures 62 of the clip. Because the forward edge face 61a of the yoke 61 is disposed closer to the aligned apertures 62 and projections 38 than is the edge face 35a of the top frame portion 35, the edge face 35a causes the upper portion 54 of the armature to be disposed forwardly of the edge face 61a in firmly abutting relationship 'with the tab member 65, as best illustrated in cross-section in FIG. 1. When the armature portion 54 is positioned in the manner previously described, the slots 56 in the portion 54 receive respective inner marginal areas of the knee portions 66. The inner marginal areas thus serve as constraining portions to constrain the armature and actuator sub-assembly 11 against downward movement out of position with respect to the assembled frame clip 1-4 and the magnet and coil sub-assembly 12. At the same time, the shoulders 55 of the armature 51 cooperate with the underside of the flank portions 37 of the top frame portion 35 to constrain the armature and actuator sub-assembly 11 from upward movement. Accordingly, in the assembly thus far described, the frame clip 14 not only constrains the armature and actuator sub-assembly 11 in pivotal engagement with the frame 32 but also biases it in a direction out of engagement with the core 40.

To complete the assembly of the relay, the foregoing assembly is secured into position with the contact and base unit 10, the downwardly directed projection 39 being received in a complementary positioning recess 74 in the base member 26, and the bight portions 60b of the leg portions 60 of the frame clip 14 being engaged, as best shown in FIGS. 1 and 2, under engagement means such as a pair of shoulders 75, respectively, which are disposed one on each side of the base member 26.

'With the relaythus assembled, electrical connections to the coil 43 are made by wires electrically connecting the terminals 45 of'the coil 43 to a pair of terminals 45a, respectively, which extend through the base member 26 in a fashion similar'to the terminal portions 19a, 24a, and 25a and are adapted for connection to an external source of'power.--

Becausethe armature and actuatorsub-assembly 11 is biased away from the core '40 by the tab member 65 of the frame clip 14, the actuator 50 normally urges the movable. contact 16 of each pole into engagement with its associatedstationary contact 21 when the coil 43 is unenergized, as shown in FIG. 1. Accordingly, it is evident that in order to maintain the contacts '16 and 21 closed, thebiasingforce'of "the tab member 65 must be sufficiently'strong to overcome the combined force of the springs 17 which tend to urge the contacts 16 toward their associatedstationarycontacts 22. When thecoil 43 is energized, the electromagnetic forceof attraction between the armature 51 and the core 40 is'sufiicient to overcome the'biasing force acting through the tab65 and, consequently, the armature 51 is drawn into engagement with the 'core 40 thereby permitting the movable contacts 16 to close against the stationary contacts 22. Hence, the contact 21 and the movable contact 16 constitute, for each pole, a normally-closed pair of contacts while the stationary'contact 22 and the contact 16 constitute, for each pole, a normally-open pair of contacts.

Therelay may, if desired, be fitted with a protective cover 80 (FIG. 1). A preferred embodiment of the cover 80 has a strut or other tab portion 81 depending from the top thereof and adapted for abutting engagement with the upwardly directed tab 49 of the frame 32 thereby to permit proper location of the cover over the relay. The cover is secured to the relay by engagement with a pairof projections 82 (FIGS. 2 and 3) on the base member 26 or, alternatively when the relay is used with a pin-. type plug-in connector as shown in FIG. 1, by screws 84 threadedly received through a lower portion of the cover in a pair of flanges 85 of the plug-in connector 29.

An alternative form of protective cover is illustrated in FIG. 7 wherein a cover 86 is provided with a manual operating means, such as a manual operator 87, received in an apertured guide 88, the apertured guide being preferably molded integrally with the cover 86. The manual operator 87 comprises a push-button portion 89 and an actuating portion 90 having a narrowed shank portion 91. The push-button portion 89 and the actuating portion 90 preferably comprise separate pieces in order to facilitate assembly of the operator 87 in the guide 88 of the cover 86. i A

In assembling the operator 87 in the cover 86, the shank portion 91 of the actuating portion 90 is inserted into the guide 88 from the insideof the cover 86. A spring 92 is then positioned coaxially on the shank portion 91 from the outside of the cover 86, the spring being received in the guide 88 with its inner end bearing upon an inner shoulder 94 of the guide. With the components of the operator 87 positioned as thus far described, the pushbutton portion 89 is secured into assembledrelationship with the shank portion 91 and the actuating portion 90. This may be accomplished by providing the push-button 89 with a narrow bore (not shown) which receives the end of the shank portion 91 in an interference fit or, altematively, by providing other interengageable fastening means on the push-button portion 89 and the end of the shank portion 91.

Thus assembled, the manual operator 87 is biased by the spring 92 in a direction (upwardly in FIG. 7) wherein the push-button portion 89 extends outwardly of the cover 86, the spring 92 being retained in the guide 88. A shoulder 95 on the actuating portion 90 cooperates with the inner end of the guide 88 to limit the upward movement of the operator 87.

would occur upon energization of the relay coil. As

illustrated in FIG. 7, the barriers 97a are shaped somewhat diiferently from the previously described barriers 50a in order to provide a proper camming action upon operation of the manual operator 87; in all other respects,

however, the relay structure is identical to that heretofore described in reference to FIGS. l-6.

Having thus described my invention, I claim:

1. An electromagnetic relay comprising a magnetic frame, a magnet core secured to the frame, a coil surrounding the core, an armaturepivotally engaging the frame for movement toward and away from the core about a pivotal axis disposed intermediate the ends of said armature, a supporting base, contact means supported by the base, a contact actuator carried by the armature and movable therewith, and a one-piece spring clip securing the frame to the base and including constraining means for non-resiliently constraining the armature from movement in at least one direction out of pivotal engagement with the frame, and said clip further including biasing means acting upon the armature at the side of saidpivotal axis farthest from the core and urging the armature away from the core thereby to urge the contact actuator to a position in engagement with the contact means.

2. An electromagnetic relay in accordance with claim 1 wherein said clip includes a central portion and wherein said biasing means comprises an overhanging portion of said clip, said overhanging portion including a pair of bent-over knee portions joining said overhanging portion to said central portion and including a tab member disposed between said knee portions.

3. An electromagnetic relay comprising a magnet frame, a magnet core secured to the frame, a coil surrounding the core, an armature pivotally engaging the frame for movement toward and away from the core, a supporting base, contact means supported by the base, a contact actuator carried by the armature and movable therewith, and a one-piece spring clip securing the frame to the base and retaining the armature in pivotal engagement with the frame, said clip including a central portion and biasing means urging the armature away from the core and urging the contact actuator to a position in engagement with the contact means, said biasing means comprising an overhanging portion of said clip, said overhanging portion including a pair of bent-over knee portions joining said overhanging portion to said central portion and including a tab member disposed between said knee portions.

4. A relay in accordance with claim 3 wherein said spring clip includes a pair of spaced leg portions disposed generally parallel to each other and-joined by said central portion, said leg portions each comprising a pair ofelongated members and a bight portion joining said elongated members at their ends remote from said central portion, and said central portion and said overhanging portion define an opening therebetween for receiving the armature.

5. An electromagnetic relay in which a magnet and coil sub-assembly, an armature and contact actuator sub-assembly, and a contact and base unit are secured together in operative relationship solely by a spring clip which also serves as a biasing means for the armature, said relay comprising a magnet frame, a core fixedly supported by said frame, an electromagnetic coil surrounding said core, a substantially fiat armature pivotally engaging said frame for pivotal movement toward and away from said core about a pivotal axis disposed intermediate the ends of said armature, a supporting base, a plurality of contact assemblies supported by the base, and a one-piece spring clip comprising constraining means, biasing means and engagement means, said constraining means non-resiliently constraining said armature from movement in at least one direction out of pivotal engagement with said frame, said biasing means acting upon said armature at the side of said pivotal axis farthest from said core to urge said armature in a direction about its pivotal axis away from said core, and said engagement means cooperating with said frame and said base to removably secure said frame to said base.

6. An electromagnetic relay in accordance with claim wherein said magnet frame includes first and second frame portions disposed at substantially a right angle to each other, said core is supported at one end by said first frame portion, and said second frame portion has a pair of flank portions defining a recess therebetween for receiving the armature in pivotal engagement with the frame.

' 7. An electromagnetic relay according to claim 6 wherein said supporting base includes positioning means formed in said base and cooperating with said first frame portion to constrain said frame in proper alignment with said base and including a pair of shoulders on said base, said shoulders being engaged by said engagement means of the spring clip for removably securing the clip and magnetic frame to said base.

8. An electromagnetic relay comprising a magnet frame, a magnet core secured to the frame, a coil surrounding the core, an armature pivotally engaging the frame for movement toward and away from the core, a supporting base, contact means supported by the base, a contact actuator carried by the armature and movable therewith, and a one-piece spring clip securing the frame to the base and retaining the armature in pivotal engagement with the frame, said clip including biasing means urging the armature away from the core and urging the contact actuator to a position in engagement with the contact means, said clip further including a pair of spaced leg portions disposed generally parallel to each other and joined by a central portion, said central portion and said frame having mutually interengaging means constraining said clip in alignment with said frame, engagement means on said base, and each of said leg portions having engagement means which cooperate with said engagement means on said base to removably secure said clip and said frame to said base.

9. A relay in accordance with claim 8 wherein each of said leg portions comprises a pair of elongated members joined at their ends remote from said central portion by a bight portion constituting said engagement means, and wherein said engagement means on said base comprises a pair of shoulders, said shoulders being ongaged by said bight portions of said leg portions, respectively, for removably securing said clip and said frame to said base.

10. An electromagnetic relay comprising an armature, a magnet frame having a pair of flank portions which define a recess for receiving the armature in pivotal engagement with the frame, a magnet core secured to the frame, a coil surrounding the core, said armature pivotally engaging the frame in said recess for movement toward and away from the core and including a narrowed portion defining, and disposed intermediate of, a pair of shoulders, said armature further having, in said narrowed portion, a pair of transversely aligned slots spaced from said shoulders and opening into the marginal edges of said narrowed portion, a supporting base, contact means supported by the base, a contact actuator carried bythe armature and movable therewith, and a unitary spring clip securing the frame to the base and retaining the armature in said recess in pivotal engagement with the frame,

a a said clip including biasing means urging the, armature away from the core and urging the contact actuator to a position in engagement with the contact means, said clip further including constraining portions received in said aligned slots, respectively, said constraining portions,.

together with said biasing means, constraining; the armature in pivotal engagement with said frame.

11. An electromagneticrelay n accordance with claim 10 wherein said spring clip includes a central portion andv an overhanging portion having a pair of bent-over knee portions joining said overhanging portion vto said central portion so as to define an opening bounded by said central portion and said overhanging portion, said narrowed" portion of said armature being received in said opening, and said constraining portions comprise the inner marginal areas of said knee portions. 4

12. An electromagnetic relay in which -a coil subassembly, an armature and contact actuator subassembly, and' a contact and base unit are secured to:

gether in operative relationship solely by a spring clip,

which also serves as a biasing means for the armature, said relay comprising a magnet frame including first and second frame portions disposed at substantially a right. angle to each other, a core fixedly supported at one end by said first frame portion, said second frame portion having a pair of flank portions defining a recess therebetween, an electromagnetic coil surrounding, said core, a-

substantially fiat generally rectangular armature overlying the other end of said core and including a narrowed portion defining, and disposed intermediate of, a pair of shoulders, said narrowed portion pivotally engaging said second frame portion in said recess for pivotal movement.

toward and away from said other end of said core, a supporting base, a plurality of contact assemblies supported by the base, and a unitary spring clip comprising constraining means, biasing means and engagement means, said constraining means together with said biasing means, constraining said armature in pivotal engagement with said second frame portion, said biasing means urging said armature in a direction about its point of pivotal engagement with said second frame portion away from said core, said egnage-ment means cooperating with said frame and said base to removably secure said frame to said base, said narrowed portion of said armature further having a pair of transversely aligned slots spaced fromsaid shoulders and. opening into the marginal edges of said narrowed portion, and said constraining means of said clip being received in said slots.

13. An electromagnetic relay comprising a magnet frame, a magnet core secured to the frame, a coil surrounding the core, an armature pivotally engaging the frame for movement toward and away from the core, :a.

to the base and retaining the armature in pivotal engage ment with the frame, said clip including biasing means urging the armature away from the core and-urging the contact actuator to a position in engagement with the contact means, said contact actuator having a plurality of barriers provided with inclined camming sufaces, a cover for said relay, and a manual operating means carried by the cover, said manual operating means having an actuating portion which, upon operation of the manual operating means, engages the inclined camming surface of one barrier thereby to urge the contact actuator to a position out of engagement with the contact means and causing operation of said contact means.

3,211,854 10/19 65 Bengtsson 335 278 3,242,285 3/1966 Obszarney etal. 335296 BERNARD A. GILHEANY, Primary Examiner.

magnet, and l 

